Angled-Mold Core Actuating Mechanism
The present invention provides an angled-mold core actuator (180, 280, 380). When actuated, an angled-cavity forming core (158) is extended into a mold cavity defined by a mold insert (154). The angled-cavity forming core (158) is disposed at a 3-dimensional angle into the mold insert (154) to form a cavity (104) in a molded product. The angled-cavity forming core is actuated by a driven pin (186, 286, 386) of the angled-mold core actuator (180, 280, 380).
The present invention relates to injection or compression molding, and more particularly to an angled-mold core actuating mechanism for use with injection or compression molding.
BACKGROUNDInjection or compression molding is a common manufacturing process used to produce plastic products, especially those that have fine or intricate shapes and finishing. In the process, molten thermoplastic or thermosetting plastic material is injected or transferred into a mold cavity and after allowing the molten materials to cool and at least partially harden to take on the shape of the mold cavity, the mold plates that define the mold cavity are opened to release a molded product. When an angled-feature (such as, a groove, a projection, a thread or hollow cavity) is formed in the molded product, the moveable-mold half is prevented from being moved away from the stationary-mold half or the molded product is prevented from being released from the moveable- or stationary-mold half. For example, when an angled-cavity is to be formed in the molded product, a mold core positioned at an angle must moveably extend into the mold cavity during the molding process for the molten material to take the shape of the product and cavity, to cool and solidify sufficiently before the mold core is retracted and mold plates are opened for the molded product to be removed. As the mold core is at an angle (that is, the angled-feature is not aligned along the planes of opening of the relevant mold plates), the angled-cavity mold core must be retracted before the relevant mold plates can be opened.
A conventional mold core drive or actuating mechanism uses a system of cams and slides, often together with a fluid actuator system. Such a conventional system is complicated, thus making it difficult to assemble and difficult to reconfigure; often it becomes unreliable or difficult to maintain, for example, due to accumulated deviations and tolerances, and invariably costly to make. The size of such a conventional mold core drive mechanism also makes it difficult to be arranged on a mold assembly to manufacture a small plastic product with an angled-feature, such as, an inkjet cartridge housing having slanting internal cavities. There is, therefore, a need to provide an angled-mold core drive mechanism that is simple in structure, compact in size and easy to assemble and maintain.
SUMMARYThe following presents a simplified summary to provide a basic understanding of the present invention. This summary is not an extensive overview of the invention, and is not intended to identify key features of the invention. Rather, it is to present some of the inventive concepts of this invention in a generalised form as a prelude to the detailed description that is to follow.
The present invention seeks to provide a linear and axial motion transfer actuator 180, 280, 380. An advantage of the linear and axial transfer actuator is its simple structure for transferring a linear motion along a first axis to a linear motion inclined at an angle to the first axis. This motion transfer actuator is useful for driving a core 158 to form a cavity 104 that is orientated in a 3-dimensional angle during molding of a product.
In one embodiment, the present invention provides a linear and axial motion transfer apparatus comprising: an actuator body having two bores disposed axially at an angle to each other; a drive pin and a driven pin separately disposed in the two bores so that the drive and driven pins are slidably guided for reciprocation in the respective bores; and a channel for communicating between the two bores, with the channel being filled with an incompressible material so that when the drive pin is axially displaced, displacement of the drive pin is transmitted axially to the driven pin.
Preferably, a portion of the drive or driven pin disposed inside the actuator body has a longitudinal flat formed parallel to the longitudinal axis of the pin to cooperate with a stopper pin to prevent the pin from being inadvertently displaced out of the actuator body.
Preferably, the incompressible material comprises a series of metal balls, oil or grease.
Preferably, a free end of the driven pin is configured as a cavity forming core in association with a mold insert that defines a mold cavity. Preferably, the cavity forming core is separate from the driven pin such that an end of the cavity forming core adjacent the driven pin is journaled in a holder and the holder is operable to slide with respect to the mold insert.
In another embodiment, the present invention provides a method for forming a molded product having cavity disposed at a 3-dimensional angle. The method comprises: transferring translation of a drive pin to a driven pin, wherein the drive and driven pins are disposed at an angle to each other; actuating the driven pin to drive an angled-cavity forming core into a mold cavity, wherein the angled-cavity forming core is disposed at a 3-dimensional angle in the mold cavity; filling the mold cavity with a molten compound and allowing the molten compound to cool and to solidify for it to take the shape of the mold cavity and angled-cavity forming core; and retracting the angled-cavity forming core and then opening the mold supporting the mold insert, which defines the mold cavity, to release a molded product.
In yet another embodiment, the present invention provides an insert molding method. The insert molding method comprises: transferring translation of a drive pin to a driven pin of the angled-motion transfer apparatus according to any one of claims 1-13; actuating the driven pin to place an insert, which is disposed at an end of an angled-cavity forming core, into a mold cavity, wherein the angled-cavity forming core is disposed at a 3-dimensional angle in the mold cavity; filling the mold cavity with a molten compound in a first molding step and allowing the molten compound to cool and to solidify for it to take the shape of the mold cavity and to support the insert; releasing the insert from the end of the angled-cavity forming core and then retracting the angled-cavity forming core; filling the cavity created by the retracted angled-cavity forming core with a molten compound in a second molding step and allowing the molten compounds to cool and harden; and opening the mold supporting the mold insert to release a molded product.
This invention will be described by way of non-limiting embodiments of the present invention, with reference to the accompanying drawings, in which:
One or more specific and alternative embodiments of the present invention will now be described with reference to the attached drawings. It shall be apparent to one skilled in the art, however, that this invention may be practised without such specific details. Some of the details may not be described at length so as not to obscure the invention. For ease of reference, common reference numerals or series of numerals will be used throughout the figures when referring to the same or similar features common to the figures.
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While specific embodiments have been described and illustrated, it is understood that many changes, modifications, variations and combinations thereof could be made to the present invention without departing from the scope of the present invention. For example, the longitudinal flat surfaces on the drive and driven pins may not be provided but the drive or driven pin may have a step, the shoulder of which is used to prevent the pin from being inadvertently displaced out of the actuator body. In another example, the drive pin may be actuated independently by an external means, such as, a solenoid or a fluid cylinder; this embodiment is useful when the angled-cavity forming core 158 is employed to place an insert into the mold cavity during a first stage molding and the angled-cavity forming core 158 is then retracted before a second stage molding is completed and the mold plates are opened.
Claims
1. A 3-dimensional angled cavity forming apparatus comprising:
- an actuator body having two bores disposed axially at an angle to each other;
- a drive pin and a driven pin separately disposed in the two bores so that the drive and driven pins are slidably guided for reciprocation in the respective bore; wherein a portion of the drive or driven pin disposed inside the actuator body has a longitudinal flat formed parallel to the longitudinal axis of the relevant pin;
- a stopper pin disposed in the actuator body to cooperate with the longitudinal flat formed on the drive or driven pin;
- a free end of the driven pin is configured as a cavity forming core in association with a mold insert and defines a 3-dimensional cavity within the mold insert; and
- a channel of gradual changing direction for communicating between the two bores, with the channel being filled with an incompressible material so that when the drive pin is axially displaced, displacement of the drive pin is transmitted axially to the driven pin.
2. (canceled)
3. (canceled)
4. An apparatus according to claim 1, wherein the incompressible material comprises a series of metal balls.
5. An apparatus according to claim 1, wherein the incompressible material is oil or grease.
6. An apparatus according to claim 5, further comprising a seal disposed between the drive or driven pin and the actuator body to prevent the oil or grease from leaking out.
7. (canceled)
8. An apparatus according to claim 1, wherein the cavity forming core is retracted before the mold supporting the mold insert is opened.
9. An apparatus according to claim 8, wherein the cavity forming core is separate from the driven pin such that an end of the cavity forming core adjacent the driven pin is journaled in a holder and the holder is operable to slide with respect to the mold insert.
10. An apparatus according to claim 9, further comprising a compression spring disposed to bias the holder against the mold insert, so that the cavity forming core is retracted from the mold cavity before the mold is opened, and the cavity forming core is inserted into the mold cavity after the mold is closed.
11. An apparatus according to claim 9, wherein the cavity forming core is disposed at an angle to the driven pin.
12. An apparatus according to claim 8, wherein the cavity forming core is configured to place an insert during molding.
13. An apparatus according to claim 10, wherein the end of the drive pin adjacent the mold opening has a spring to take up dimensional deviations and tolerances accumulated along the motion transfer path.
14. A method for forming a 3-dimensional angled-cavity in a molded product, the method comprising:
- transferring translation of a drive pin to a driven pin, wherein the drive and driven pins are disposed at an angle to each other;
- actuating the driven pin to drive an angled-cavity forming core into a mold cavity, wherein the angled-cavity forming core is disposed at a 3-dimensional angle in the mold cavity;
- filling the mold cavity with a molten compound and allowing the molten compound to cool and to solidify for it to take the shape of the mold cavity and angled-cavity forming core; and
- retracting the angled-cavity forming core and then opening the mold supporting the mold insert, which defines the mold cavity, to release a molded product.
15. A method according to claim 14, wherein the angled-cavity forming core is journaled in a holder and the holder is slidably disposed with respect to the mold insert defining the mold cavity.
16. A method according to claim 15, further comprises biasing the holder against the mold insert so that the angled-cavity forming core is retracted from the mold cavity when the mold is opened.
17. A method according to claim 14, wherein actuating the drive pin is carried out by closing the mold supporting the mold insert.
18. A method according to claim 14, wherein actuating the drive pin is carried out by a solenoid or a fluid cylinder.
19. An insert molding method comprising:
- transferring translation of a drive pin to a driven pin of the angled-motion transfer apparatus as defined in claim 1;
- actuating the driven pin to place an insert, which is disposed at an end of an angled-cavity forming core, into a mold cavity, wherein the angled-cavity forming core is disposed at a 3-dimensional angle in the mold cavity;
- filling the mold cavity with a molten compound in a first molding step and allowing the molten compound to cool and to solidify for it to take the shape of the mold cavity and to support the insert;
- releasing the insert from the end of the angled-cavity forming core and then retracting the angled-cavity forming core;
- filling the cavity created by the retracted angled-cavity forming core with a molten compound in a second molding step and allowing the molten compounds to cool and harden; and
- opening the mold supporting the mold insert to release a molded product.
Type: Application
Filed: Feb 18, 2013
Publication Date: Dec 31, 2015
Inventor: Heng Man HOONG (Singapore)
Application Number: 14/768,453